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Fairy Overdrive

I have just fitted a Fairy OD to my 8 month old gearbox.
To test it before i went out on the roads i knocked the transfer box into neutral and ran through all the gears with and without the OD engaged.
In both 3rd and 4th with and without the overdrive engaged there were a few crunching noises like a piece of metal was going between the teeth.
I have removed the overdrive and the gears run perfectly without the OD.
Drained the oil and no obvious chunkes of metal.

Does anyone know what the crunching is and why only in 3rd and 4th?
Just realised i had used the original tab washer from the gearbox and not the shorter one if that is the difference?